Method of manufacturing an insulated pipeline

ABSTRACT

A method of manufacturing an insulated pipeline.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is the National Stage patent application for PCTpatent application serial number PCT/US2003/024779, attorney docketnumber 25791.125.02, filed on Aug. 08, 2003, which claimed the benefitof the filing dates of (1) U.S. provisional patent application Ser. No.60/407,442, attorney docket no 25791.125, filed on Aug. 30, 2002, thedisclosure of which is incorporated herein by reference.

The present application is related to the following: (1) U.S. patentapplication Ser. No. 09/454,139, attorney docket no. 25791.03.02, filedon Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913,attorney docket no. 25791.7.02, filed on Feb. 23, 2000, (3) U.S. patentapplication Ser. No. 09/502,350, attorney docket no. 25791.8.02, filedon Feb. 10, 2000, (4) U.S. Pat. No. 6,328,113, (5) U.S. patentapplication Ser. No. 09/523,460, attorney docket no. 25791.11.02, filedon Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895,attorney docket no. 25791.12.02, filed on Feb. 24, 2000, (7) U.S. patentapplication Ser. No. 09/511,941, attorney docket no. 25791.16.02, filedon Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946,attorney docket no. 25791.17.02, filed on Jun. 7, 2000, (9) U.S. patentapplication Ser. No. 09/559,122, attorney docket no. 25791.23.02, filedon Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635,attorney docket no. 25791.25.02, filed on Jul. 9, 2000, (11) U.S.provisional patent application Ser. No. 60/162,671, attorney docket no.25791.27, filed on Nov. 1, 1999, (12) U.S. provisional patentapplication Ser. No. 60/154,047, attorney docket no. 25791.29, filed onSep. 16, 1999, (13) U.S. provisional patent application Ser. No.60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999, (14)U.S. provisional patent application Ser. No. 60/159,039, attorney docketno. 25791.36, filed on Oct. 12, 1999, (15) U.S. provisional patentapplication Ser. No. 60/159,033, attorney docket no. 25791.37, filed onOct. 12, 1999, (16) U.S. provisional patent application Ser. No.60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (17)U.S. provisional patent application Ser. No. 60/165,228, attorney docketno. 25791.39, filed on Nov. 12, 1999, (18) U.S. provisional patentapplication Ser. No. 60/221,443, attorney docket no. 25791.45, filed onJul. 28, 2000, (19) U.S. provisional patent application Ser. No.60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000, (20)U.S. provisional patent application Ser. No. 60/233,638, attorney docketno. 25791.47, filed on Sep. 18, 2000, (21) U.S. provisional patentapplication Ser. No. 60/237,334, attorney docket no. 25791.48, filed onOct. 2, 2000, (22) U.S. provisional patent application Ser. No.60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001, (23)U.S. provisional patent application Ser. No. 60/262,434, attorney docketno. 25791.51, filed on Jan. 17, 2001, (24) U.S. provisional patentapplication Ser. No. 60/259,486, attorney docket no. 25791.52, filed onJan. 3, 2001, (25) U.S. provisional patent application Ser. No.60/303,740, attorney docket no. 25791.61, filed on Jul. 6, 2001, (26)U.S. provisional patent application Ser. No. 60/313,453, attorney docketno. 25791.59, filed on Aug. 20, 2001, (27) U.S. provisional patentapplication Ser. No. 60/317,985, attorney docket no. 25791.67, filed onSep. 6, 2001, (28) U.S. provisional patent application Ser. No.60/3318,386, attorney docket no. 25791.67.02, filed on Sep. 10, 2001,(29) U.S. utility patent application Ser. No. 09/969,922, attorneydocket no. 25791.69, filed on Oct. 3, 2001 (30) U.S. utility patentapplication Ser. No. 10/016,467, attorney docket no. 25791.70, filed onDec. 10, 2001, (31) U.S. provisional patent application Ser. No.60/343,674, attorney docket no. 25791.68, filed on Dec. 27, 2001, (32)U.S. provisional patent application Ser. No. 60/346,309, attorney docketno 25791.92, filed on Jan. 7, 2002, (33) U.S. provisional patentapplication Ser. No. 60/372,048, attorney docket no. 25791.93, filed onApr. 12, 2002, (34) U.S. provisional patent application Ser. No.60/380,147, attorney docket no. 25791.104, filed on May 6, 2002, (35)U.S. provisional patent application Ser. No. 60/387,486, attorney docketno. 25791.107, filed on Jun. 10, 2002, (36) U.S. provisional patentapplication Ser. No. 60/387,961, attorney docket no. 25791.108, filed onJun. 12, 2002, (37) U.S. provisional patent application Ser. No.60/391,703, attorney docket no. 25791.90, filed on Jun. 26, 2002, (38)U.S. provisional patent application Ser. No. 60/397,284, attorney docketno. 25791.106, filed on Jul. 19, 2002, and (39) U.S. provisional patentapplication Ser. No. 60/398,061, attorney docket no. 25791.110, filed onJul. 24, 2002, (40) U.S. provisional patent application Ser. No.60/405,610, attorney docket no. 25791.119, filed on Aug. 23, 2002, and(41) U.S. provisional patent application Ser. No. 60/405,394, attorneydocket no. 25791.120, filed on Aug. 23, 2002, the disclosures of whichare incorporated herein by reference.

BACKGROUND OF THE INVENTION

This invention relates generally to oil and gas pipelines, and inparticular to manufacturing oil and gas pipelines to facilitate oil andgas exploration and production.

Conventionally, when oil and/or gas is transported from an offshoreproduction facility to another offshore and/or onshore production,processing, and/or transport facility, the oil and/or gas is conveyedthrough an insulated pipeline positioned on the ocean floor. Theinsulated pipeline is used in order to minimize cooling of the oiland/or gas by the ocean water. Excessive cooling of the oil and/or gascan cause undesirable side effects, such as, for example, wax formation,that can severely effect the efficiency of the conveyance of the oiland/or gas. The insulated pipeline is manufactured onshore in aconventional manner, rolled up onto a dispensing reel, and then placedonto a ship for transport to the ultimate location of the insulatedpipeline. The insulated pipeline is then unreeled off of the dispensingreel on the ship, lowered onto the ocean, and positioned on the oceanfloor. The cost of purchasing and positioning the pre-fabricatedinsulated pipelines for typical offshore production fields can easilyexceed the total cost of the production wells themselves.

The present invention is directed to overcoming one or more of thelimitations of the existing procedures for transporting oil and/or gasproduction using insulated pipelines.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a method ofmanufacturing an insulated pipeline has been provided that includespositioning a first pipe having a plurality of spaced apart resilientsleeves coupled to the exterior surface of the first pipe within asecond pipe, and radially expanding and plastically deforming the firstpipe until the resilient sleeves engage the interior surface of thesecond pipe.

According to another aspect of the present invention, a system formanufacturing an insulated pipeline is provided that includes means forpositioning a first pipe having a plurality of spaced apart resilientsleeves coupled to the exterior surface of the first pipe within asecond pipe, and means for radially expanding and plastically deformingthe first pipe until the resilient sleeves engage the interior surfaceof the second pipe.

According to another aspect of the present invention, a method ofmanufacturing an insulated pipeline that includes an inner rigid pipepositioned within, coupled to, and thermally insulated from an outerrigid pipe is provided that includes manufacturing the insulatedpipeline by radially expanding and plastically deforming the inner rigidpipe within the outer rigid pipe.

According to another aspect of the present invention, a system formanufacturing an insulated pipeline including an inner rigid pipepositioned within, coupled to, and thermally insulated from an outerrigid pipe is provided that includes means for manufacturing theinsulated pipeline by radially expanding and plastically deforming theinner rigid pipe within the outer rigid pipe.

According to another aspect of the present invention, a thermallyinsulated pipeline is provided that includes a plastically deformedfirst pipe, a plurality of spaced apart resilient sleeves coupled to theexterior of the first pipe, and a second pipe coupled to the resilientsleeves.

According to another aspect of the present invention, a method ofoperating a hydrocarbon production system for processing hydrocarbonsthat includes one or more hydrocarbon production sources and one or morehydrocarbon production destinations, is provided that includes conveyinghydrocarbons between the hydrocarbon production sources and thehydrocarbon destinations using one or more insulated pipelines, andmanufacturing at least one of the insulated pipelines by radiallyexpanding and plastically deforming an inner rigid pipe within an outerrigid pipe.

According to another aspect of the present invention, a method ofmanufacturing an insulated wellbore casing within a borehole thattraverses a subterranean formation and includes a first wellbore casingcoupled to and positioned within the wellbore is provided that includespositioning a second wellbore casing having a plurality of spaced apartresilient sleeves coupled to the exterior surface of the first pipewithin the first wellbore casing, and radially expanding and plasticallydeforming the second wellbore casing until the resilient sleeves engagethe interior surface of the second pipe.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary cross-sectional illustration of a first pipehaving a plurality of spaced apart resilient sleeves positioned within asecond pipe.

FIG. 2 is a fragmentary cross-sectional illustration of the apparatus ofFIG. 1 during the radial expansion and plastic deformation of the firstpipe within the second pipe.

FIG. 3 is a fragmentary cross-sectional illustration of the apparatus ofFIG. 2 after completing the radial expansion and plastic deformation ofthe first pipe within the second pipe.

FIG. 4 is a fragmentary cross sectional of the positioning of theapparatus of FIG. 3 beneath the ocean floor.

FIG. 5 is a schematic illustration of the use of the apparatus of FIGS.3 and/or 4 to convey hydrocarbons between and among hydrocarbonproduction facilities and hydrocarbon delivery and/or processingfacilities.

FIG. 6 is a fragmentary cross sectional illustration of an alternativeembodiment of the apparatus of FIG. 1 in which a thermal insulationmaterial is injected into the annulus between the first and second pipesprior to radially expanding and plastically deforming the second pipe.

FIG. 7 is a fragmentary cross-sectional illustration of the apparatus ofFIG. 6 during the radial expansion and plastic deformation of the firstpipe within the second pipe.

FIG. 8 is a fragmentary cross-sectional illustration of the apparatus ofFIG. 7 after completing the radial expansion and plastic deformation ofthe first pipe within the second pipe.

FIG. 9 is a fragmentary cross sectional illustration of an alternativeembodiment of the apparatus of FIG. 3 in which a supply of thermalinsulation material is injected into the annulus between the first andsecond pipes after the radial expansion and plastic deformation of thesecond pipe.

FIG. 9 a is a cross sectional illustration of the apparatus of FIG. 9.

FIG. 10 is a fragmentary cross sectional illustration of the apparatusof FIG. 9 after injecting a thermal insulation material into the annulusbetween the first and second pipes.

FIG. 11 is a fragmentary cross sectional illustration of an alternativeembodiment of the apparatus of FIG. 1 in which tubular sections ofinsulating material are coupled to the exterior surface of the firstpipe between and interleaved among the resilient sleeves.

FIG. 12 is a fragmentary cross-sectional illustration of the apparatusof FIG. 11 during the radial expansion and plastic deformation of thefirst pipe within the second pipe.

FIG. 13 is a fragmentary cross-sectional illustration of the apparatusof FIG. 12 after completing the radial expansion and plastic deformationof the first pipe within the second pipe.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring to FIG. 1, a first pipe 10 that defines a passage 10 a andincludes a plurality of resilient spaced apart sleeves 12 that arecoupled to the exterior surface of the first pipe is positioned within asecond pipe 14. In several exemplary embodiments, the first and secondpipes, 10 and 14, are metallic and may each include a plurality of pipesthreadably coupled together end to end, and the sleeves 12 are metallicand/or rubber and/or ceramic and/or composite. In an exemplaryembodiment, the thermal conductivity of the sleeves 12 is less than thethermal conductivity of the second pipe 14 in order to reduce thetransmission of thermal energy from the first pipe 10 to the second pipeafter the first pipe is radially expanded and plastically deformed. Inan exemplary embodiment, the first pipe 10 is supported within thesecond pipe 12 by a conventional support member 16, and the second pipe14 is maintained in a substantially stationary position by coupling thesecond pipe to a preexisting structure 18 in a conventional manner. Inseveral exemplary embodiments, the preexisting structure 18 may, forexample, be a subterranean formation, the surface of the earth, awellbore, another pipeline, a conventional pipe fixturing device, and/ora conventional pipe support member.

In several exemplary embodiments, the first pipe 10 may, for example, beassembled and/or the first pipe may, for example, be positioned andsupported within the second pipe 14 using one or more of the methods andapparatus disclosed in one or more of the following: (1) U.S. patentapplication Ser. No. 09/454,139, attorney docket no. 25791.03.02, filedon Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913,attorney docket no. 25791.7.02, filed on Feb. 23, 2000, (3) U.S. patentapplication Ser. No. 09/502,350, attorney docket no. 25791.8.02, filedon Feb. 10, 2000, (4) U.S. Pat. No. 6,328,113, (5) U.S. patentapplication Ser. No. 09/523,460, attorney docket no. 25791.11.02, filedon Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895,attorney docket no. 25791.12.02, filed on Feb. 24, 2000, (7) U.S. patentapplication Ser. No. 09/511,941, attorney docket no. 25791.16.02, filedon Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946,attorney docket no. 25791.17.02, filed on Jun. 7, 2000, (9) U.S. patentapplication Ser. No. 09/559,122, attorney docket no. 25791.23.02, filedon Apr. 26, 2000, (10) PCT patent application Ser. No. PCT/US00/18635,attorney docket no. 25791.25.02, filed on Jul. 9, 2000, (11) U.S.provisional patent application Ser. No. 60/162,671, attorney docket no.25791.27, filed on Nov. 1, 1999, (12) U.S. provisional patentapplication Ser. No. 60/154,047, attorney docket no. 25791.29, filed onSep. 16, 1999, (13) U.S. provisional patent application Ser. No.60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999, (14)U.S. provisional patent application Ser. No. 60/159,039, attorney docketno. 25791.36, filed on Oct. 12, 1999, (15) U.S. provisional patentapplication Ser. No. 60/159,033, attorney docket no. 25791.37, filed onOct. 12, 1999, (16) U.S. provisional patent application Ser. No.60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (17)U.S. provisional patent application Ser. No. 60/165,228, attorney docketno. 25791.39, filed on Nov. 12, 1999, (18) U.S. provisional patentapplication Ser. No. 60/221,443, attorney docket no. 25791.45, filed onJul. 28, 2000, (19) U.S. provisional patent application Ser. No.60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000, (20)U.S. provisional patent application Ser. No. 60/233,638, attorney docketno. 25791.47, filed on Sep. 18, 2000, (21) U.S. provisional patentapplication Ser. No. 60/237,334, attorney docket no. 25791.48, filed onOct. 2, 2000, (22) U.S. provisional patent application Ser. No.60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001, (23)U.S. provisional patent application Ser. No. 60/262,434, attorney docketno. 25791.51, filed on Jan. 17, 2001, (24) U.S. provisional patentapplication Ser. No. 60/259,486, attorney docket no. 25791.52, filed onJan. 3, 2001, (25) U.S. provisional patent application Ser. No.60/303,740, attorney docket no. 25791.61, filed on Jul. 6, 2001, (26)U.S. provisional patent application Ser. No. 60/313,453, attorney docketno. 25791.59, filed on Aug. 20, 2001, (27) U.S. provisional patentapplication Ser. No. 60/317,985, attorney docket no. 25791.67, filed onSep. 6, 2001, (28) U.S. provisional patent application Ser. No.60/3318,386, attorney docket no. 25791.67.02, filed on Sep. 10, 2001,(29) U.S. utility patent application Ser. No. 09/969,922, attorneydocket no. 25791.69, filed on Oct. 3, 2001, (30) U.S. utility patentapplication Ser. No. 10/016,467, attorney docket no. 25791.70, filed onDec. 10, 2001, (31) U.S. provisional patent application Ser. No.60/343,674, attorney docket no. 25791.68, filed on Dec. 27, 2001, (32)U.S. provisional patent application Ser. No. 60/346,309, attorney docketno 25791.92, filed on Jan. 7, 2002, (33) U.S. provisional patentapplication Ser. No. 60/372,048, attorney docket no. 25791.93, filed onApr. 12, 2002, (34) U.S. provisional patent application Ser. No.60/380,147, attorney docket no. 25791.104, filed on May 6, 2002, (35)U.S. provisional patent application Ser. No. 60/387,486, attorney docketno. 25791.107, filed on Jun. 10, 2002, (36) U.S. provisional patentapplication Ser. No. 60/387,961, attorney docket no. 25791.108, filed onJun. 12, 2002, (37) U.S. provisional patent application Ser. No.60/391,703, attorney docket no. 25791.90, filed on Jun. 26, 2002, (38)U.S. provisional patent application Ser. No. 60/397,284, attorney docketno. 25791.106, filed on Jul. 19, 2002, and (39) U.S. provisional patentapplication Ser. No. 60/398,061, attorney docket no. 25791.110, filed onJul. 24, 2002, (40) U.S. provisional patent application Ser. No.60/405,610, attorney docket no. 25791.119, filed on Aug. 23, 2002, and(41) U.S. provisional patent application Ser. No. 60/405,394, attorneydocket no. 25791.120, filed on Aug. 23, 2002, the disclosures of whichare incorporated herein by reference.

Referring to FIGS. 2 and 3, the first pipe 10 is then radially expandedand plastically deformed within the second pipe 14 until the sleeves 12engage and thereby support the first pipe within the second pipe in aspaced apart relationship. In this manner, an annulus 20 is maintainedbetween the first and second pipes, 10 and 14. After completing theradial expansion and plastic deformation of the first pipe 10 within thesecond pipe 14, the first pipe is decoupled from the support member 16.As a result, a thermally insulated pipeline 22 is manufactured thatincludes the radially expanded and plastically deformed first pipe 10positioned within and coupled to the second pipe 14, the spaced apartresilient sleeves 12 that support the first pipe within the second pipe,and a plurality of tubular air gaps 20 positioned between andinterleaved among the resilient sleeves. In an exemplary embodiment, thethermal conductivities of the resilient sleeves 12 and the air gaps 20are both less than the thermal conductivities of the first and secondpipes, 10 and 14, in order to reduce the transmission of thermal energybetween the first and second pipes.

In several exemplary embodiments, the first pipe 10 is radially expandedand plastically deformed within the second pipe 14 by displacing anexpansion cone 24 within the first pipe using one or more of the methodsand apparatus disclosed in one or more of the following: (1) U.S. patentapplication Ser. No. 09/454,139, attorney docket no. 25791.03.02, filedon Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913,attorney docket no. 25791.7.02, filed on Feb. 23, 2000, (3) U.S. patentapplication Ser. No. 09/502,350, attorney docket no. 25791.8.02, filedon Feb. 10, 2000, (4) U.S. Pat. No. 6,328,113, (5) U.S. patentapplication Ser. No. 09/523,460, attorney docket no. 25791.11.02, filedon Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895,attorney docket no. 25791.12.02, filed on Feb. 24, 2000, (7) U.S. patentapplication Ser. No. 09/511,941, attorney docket no. 25791.16.02, filedon Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946,attorney docket no. 25791.17.02, filed on Jun. 7, 2000, (9) U.S. patentapplication Ser. No. 09/559,122, attorney docket no. 25791.23.02, filedon Apr. 26, 2000, (10) PCT patent application Ser. No. PCT/US00/18635,attorney docket no. 25791.25.02, filed on Jul. 9, 2000, (11) U.S.provisional patent application Ser. No. 60/162,671, attorney docket no.25791.27, filed on Nov. 1, 1999, (12) U.S. provisional patentapplication Ser. No. 60/154,047, attorney docket no. 25791.29, filed onSep. 16, 1999, (13) U.S. provisional patent application Ser. No.60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999, (14)U.S. provisional patent application Ser. No. 60/159,039, attorney docketno. 25791.36, filed on Dec. 12, 1999, (15) U.S. provisional patentapplication Ser. No. 60/159,033, attorney docket no. 25791.37, filed onOct. 12, 1999, (16) U.S. provisional patent application Ser. No.60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (17)U.S. provisional patent application Ser. No. 60/165,228, attorney docketno. 25791.39, filed on Nov. 12, 1999, (18) U.S. provisional patentapplication Ser. No. 60/221,443, attorney docket no. 25791.45, filed onJul. 28, 2000, (19) U.S. provisional patent application Ser. No.60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000, (20)U.S. provisional patent application Ser. No. 60/233,638, attorney docketno. 25791.47, filed on Sep. 18, 2000, (21) U.S. provisional patentapplication Ser. No. 60/237,334, attorney docket no. 25791.48, filed onOct. 2, 2000, (22) U.S. provisional patent application Ser. No.60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001, (23)U.S. provisional patent application Ser. No. 60/262,434, attorney docketno. 25791.51, filed on Jan. 17, 2001, (24) U.S. provisional patentapplication Ser. No. 60/259,486, attorney docket no. 25791.52, filed onJan. 3, 2001, (25) U.S. provisional patent application Ser. No.60/303,740, attorney docket no. 25791.61, filed on Jul. 6, 2001, (26)U.S. provisional patent application Ser. No. 60/313,453, attorney docketno. 25791.59, filed on Aug. 20, 2001, (27) U.S. provisional patentapplication Ser. No. 60/317,985, attorney docket no. 25791.67, filed onSep. 6, 2001, (28) U.S. provisional patent application Ser. No.60/3318,386, attorney docket no. 25791.67.02, filed on Sep. 10, 2001,(29) U.S. utility patent application Ser. No. 09/969,922, attorneydocket no. 25791.69, filed on Oct. 3, 2001, (30) U.S. utility patentapplication Ser. No. 10/016,467, attorney docket no. 25791.70, filed onDec. 10, 2001, (31) U.S. provisional patent application Ser. No.60/343,674, attorney docket no. 25791.68, filed on Dec. 27, 2001, (32)U.S. provisional patent application Ser. No. 60/346,309, attorney docketno 25791.92, filed on Jan. 7, 2002, (33) U.S. provisional patentapplication Ser. No. 60/372,048, attorney docket no. 25791.93, filed onApr. 12, 2002, (34) U.S. provisional patent application Ser. No.60/380,147, attorney docket no. 25791.104, filed on May 6, 2002, (35)U.S. provisional patent application Ser. No. 60/387,486, attorney docketno. 25791.107, filed on Jun. 10, 2002, (36) U.S. provisional patentapplication Ser. No. 60/387,961, attorney docket no. 25791.108, filed onJun. 12, 2002, (37) U.S. provisional patent application Ser. No.60/391,703, attorney docket no. 25791.90, filed on Jun. 26, 2002, (38)U.S. provisional patent application Ser. No. 60/397,284, attorney docketno. 25791.106, filed on Jul. 19, 2002, and (39) U.S. provisional patentapplication Ser. No. 60/398,061, attorney docket no. 25791.110, filed onJul. 24, 2002, (40) U.S. provisional patent application Ser. No.60/405,610, attorney docket no. 25791.119, filed on Aug. 23, 2002, and(41) U.S. provisional patent application Ser. No. 60/405,394, attorneydocket no. 25791.120, filed on Aug. 23, 2002, the disclosures of whichare incorporated herein by reference.

In several alternative embodiments, the first pipe 10 may be radiallyexpanded and plastically deformed within the second pipe 14 using otherconventional methods such as, for example, such as, for example,internal pressurization and/or roller expansion devices such as, forexample, that disclosed in U.S. patent application publication nos. U.S.2001/0045284 A1, U.S. 2002/0108756 A1, U.S. 2003/0047323 A1, and U.S.2003/0047320 A1, U.S. Pat. Nos. 6,012,523, 6,112,818, and 6,578,630,and/or International Publication Nos. WO 03/055616 A2, WO 03/048521 A2,WO 03/048520 A2, the disclosures of which are incorporated herein byreference, and/or, for example, any of the expansion methods andapparatus commercially available from Enventure Global TechnologyL.L.C., Weatherford International and/or Baker Oil Tools.

Referring to FIG. 4, in an exemplary embodiment, the preexistingstructure 18 is a subterranean formation positioned beneath a body ofwater 22 such as, for example, an ocean, bay, river, lake or other bodyof water. In this manner, fluidic materials 26 may be conveyed throughthe passage 10 a of the first pipe 10 of the insulated pipeline 22through the subterranean formation 18 below the body of water 22. Inseveral exemplary embodiments, the fluidic materials 26, may, forexample, include oil, gas, and/or other hydrocarbon materials. Inseveral exemplary embodiments, one or more of the operational proceduresillustrated and described above with reference to FIGS. 1-3 areperformed while the first and second pipes, 10 and 14, are bothpositioned within the subterranean formation 18. In this manner, theinsulated pipeline 22 may be manufactured at least partially in situ byradially expanding the first pipe 10 which provides a much more costefficient method of manufacturing an insulated pipeline.

Referring to FIG. 5, a hydrocarbon production system 28 includesinsulated pipelines 22 a, 22 b, 22 c, and 22 d, for conveyinghydrocarbon materials between and among a hydrocarbon productionfacility 30, a hydrocarbon delivery terminal 32, a hydrocarbonprocessing facility 34, and a hydrocarbon processing facility 36. In anexemplary embodiment, the hydrocarbon production facility 30 may includeone or more offshore and/or onshore production wells, the hydrocarbondelivery terminal 32 may include one or more offshore and/or onshoredelivery and/or storage terminals, and the hydrocarbon processingfacilities, 34 and 36, may include one or more processing plants forprocessing hydrocarbon materials to generate refined and/or reformulatedhydrocarbon materials. In an exemplary embodiment, the use of theinsulated pipelines 22 in the system 28 provides a number of importantbenefits. For example, the insulated pipelines 22 reduce the loss ofthermal energy from the hydrocarbon materials during transmissionthereby reducing the unwanted formation of waxes. Furthermore, theinsulated pipelines 22 also permit the material properties of thehydrocarbon products to be more precisely controlled during transmissionthereby enhancing the overall operational efficiency of the system 28.Finally, because the insulated pipelines can be manufactured in situ, byexpanding the first pipe 10 into engagement with the second pipe 14, thecost of providing the insulated pipelines 22 to the system 28 issignificantly less than using conventional pre-fabricated insulatedpipelines.

Referring to FIG. 6, in an alternative embodiment of the apparatus ofFIG. 1, a supply of thermal insulation material 38 is operably coupledto a pump 40 that in turn is operably coupled to the annulus 20 betweenthe first pipe 10 and the second pipe 14. Thermal insulation material 42is then injected into the annulus 20 between the first and second pipes,10 and 14, by operating the pump 40. The thermal insulating material 42may be any conventional injectable insulation material that may or maynot expand volumetrically or chemically react after being injected intothe annulus 20 by the pump 40. In an exemplary embodiment, the thermalconductivity of the thermal insulating material 42 is less than thethermal conductivities of both the first and second pipes, 10 and 14.

Referring to FIGS. 7 and 8, the first pipe 10 is then radially expandedand plastically deformed within the second pipe 14 until the sleeves 12engage and thereby support the first pipe within the second pipe in aspaced apart relationship. After completing the radial expansion andplastic deformation of the first pipe 10 within the second pipe 14, thefirst pipe is decoupled from the support member 16. As a result, athermally insulated pipe 44 is manufactured that includes the radiallyexpanded and plastically deformed first pipe 10 positioned within andcoupled to the second pipe 14, the spaced apart resilient sleeves 12that support the first pipe within the second pipe, and a plurality ofthermal insulating sleeves 42 positioned between and interleaved amongthe resilient sleeve 12.

Referring to FIGS. 9, 9 a, and 10, in an alternative embodiment of theapparatus of FIG. 3, one or more of the resilient sleeves 12 include oneor more longitudinal passages 44 that permit thermal insulation material42 to be injected through the longitudinal passages and into the tubularair gaps 20 between the resilient sleeves 12. As a result, a thermallyinsulated pipe 46 is manufactured that includes the radially expandedand plastically deformed first pipe 10 positioned within and coupled tothe second pipe 14, the spaced apart resilient sleeves 12 that supportthe first pipe within the second pipe, and a plurality of thermalinsulating sleeves 48 positioned between and interleaved among theresilient sleeve 12. In an exemplary embodiment, the thermalconductivities of the thermal insulating sleeves 48 are less than thethermal conductivities of both the first and second pipes, 10 and 14.

Referring to FIG. 11, in an alternative embodiment of the apparatus ofFIG. 1, a plurality of tubular thermal insulating members 50 are coupledto the exterior surface of the first pipe 10 between and interleavedamong the spaced apart resilient sleeves 12. The thermal insulatingmembers 50 may be composed of any number of conventional thermalinsulating materials. In an exemplary embodiment, the thermalconductivities of the thermal insulating members 50 are less than thethermal conductivities of both the first and second pipes, 10 and 14.

Referring to FIGS. 12 and 13, the first pipe 10 is then radiallyexpanded and plastically deformed within the second pipe 14 until thesleeves 12 engage and thereby support the first pipe within the secondpipe in a spaced apart relationship. After completing the radialexpansion and plastic deformation of the first pipe 10 within the secondpipe 14, the first pipe is decoupled from the support member 16. As aresult, a thermally insulated pipe 52 is manufactured that includes theradially expanded and plastically deformed first pipe 10 positionedwithin and coupled to the second pipe 14, the spaced apart resilientsleeves 12 that support the first pipe within the second pipe, and theplurality of thermal insulating sleeves 50 positioned between andinterleaved among the resilient sleeve 12.

A method of manufacturing an insulated pipeline has been described thatincludes positioning a first pipe having a plurality of spaced apartresilient sleeves coupled to the exterior surface of the first pipewithin a second pipe, and radially expanding and plastically deformingthe first pipe until the resilient sleeves engage the interior surfaceof the second pipe. In an exemplary embodiment, the method furtherincludes injecting an insulating material into an annulus definedbetween the first and second pipes. In an exemplary embodiment,injecting the insulating material into the annulus defined between thefirst and second pipes includes injecting the insulating material intothe annulus defined between the first and second pipes before radiallyexpanding and plastically deforming the first pipe. In an exemplaryembodiment, injecting the insulating material into the annulus definedbetween the first and second pipes includes injecting the insulatingmaterial into the annulus defined between the first and second pipesafter radially expanding and plastically deforming the first pipe. In anexemplary embodiment, the first pipe further includes a plurality ofthermal insulating sleeves coupled to the exterior surface of the firstpipe and interleaved among the resilient sleeves. In an exemplaryembodiment, positioning the first pipe having the plurality of spacedapart resilient sleeves coupled to the exterior surface of the firstpipe within the second pipe includes positioning the second pipe beneatha body of water, and positioning the first pipe having the plurality ofspaced apart resilient sleeves coupled to the exterior surface of thefirst pipe within the second pipe.

A system for manufacturing an insulated pipeline has also been describedthat includes means for positioning a first pipe having a plurality ofspaced apart resilient sleeves coupled to the exterior surface of thefirst pipe within a second pipe, and means for radially expanding andplastically deforming the first pipe until the resilient sleeves engagethe interior surface of the second pipe. In an exemplary embodiment, thesystem further includes means for injecting an insulating material intoan annulus defined between the first and second pipes. In an exemplaryembodiment, the means for injecting the insulating material into theannulus defined between the first and second pipes includes means forinjecting the insulating material into the annulus defined between thefirst and second pipes before radially expanding and plasticallydeforming the first pipe. In an exemplary embodiment, the means forinjecting the insulating material into the annulus defined between thefirst and second pipes includes means for injecting the insulatingmaterial into the annulus defined between the first and second pipesafter radially expanding and plastically deforming the first pipe. In anexemplary embodiment, the first pipe further includes a plurality ofthermal insulating sleeves coupled to the exterior surface of the firstpipe and interleaved among the resilient sleeves. In an exemplaryembodiment, the means for positioning the first pipe having theplurality of spaced apart resilient sleeves coupled to the exteriorsurface of the first pipe within the second pipe includes means forpositioning the second pipe beneath a body of water, and means forpositioning the first pipe having the plurality of spaced apartresilient sleeves coupled to the exterior surface of the first pipewithin the second pipe.

A method of manufacturing an insulated pipeline comprising an innerrigid pipe positioned within, coupled to, and thermally insulated froman outer rigid pipe, has been described that includes manufacturing theinsulated pipeline by radially expanding and plastically deforming theinner rigid pipe within the outer rigid pipe. In an exemplaryembodiment, the method further includes positioning the outer rigid pipeat a location at which the insulated pipeline will be used to conveyfluidic materials through the interior of the first pipe, andmanufacturing the insulated pipeline by radially expanding andplastically deforming the inner rigid pipe within the outer rigid pipewhile the inner and outer rigid pipes are both positioned at thelocation at which the insulated pipeline will be used to convey fluidicmaterials through the interior of the first pipe. In an exemplaryembodiment, the location at which the insulated pipeline will be used toconvey fluidic materials through the interior of the first pipe is belowa body of water.

A system for manufacturing an insulated pipeline comprising an innerrigid pipe positioned within, coupled to, and thermally insulated froman outer rigid pipe, has been described that includes means formanufacturing the insulated pipeline by radially expanding andplastically deforming the inner rigid pipe within the outer rigid pipe.In an exemplary embodiment, the system further includes means forpositioning the outer rigid pipe at a location at which the insulatedpipeline will be used to convey fluidic materials through the interiorof the first pipe, and means for manufacturing the insulated pipeline byradially expanding and plastically deforming the inner rigid pipe withinthe outer rigid pipe while the inner and outer rigid pipes are bothpositioned at the location at which the insulated pipeline will be usedto convey fluidic materials through the interior of the first pipe. Inan exemplary embodiment, the location at which the insulated pipelinewill be used to convey fluidic materials through the interior of thefirst pipe is below a body of water.

A thermally insulated pipeline has been described that includes aplastically deformed first pipe, a plurality of spaced apart resilientsleeves coupled to the exterior of the first pipe, and a second pipecoupled to the resilient sleeves. In an exemplary embodiment, theinsulated pipeline further includes thermal insulating materialpositioned within an annulus defined between the first and second pipesand interleaved among the resilient sleeves. In an exemplary embodiment,one or more of the resilient sleeves include one or more longitudinalpassages. In an exemplary embodiment, at least some of the thermalinsulating material is positioned within the longitudinal passages.

A method of operating a hydrocarbon production system for processinghydrocarbons that includes one or more hydrocarbon production sourcesand one or more hydrocarbon production destinations has been describedthat includes conveying hydrocarbons between the hydrocarbon productionsources and the hydrocarbon destinations using one or more insulatedpipelines, and manufacturing at least one of the insulated pipelines byradially expanding and plastically deforming an inner rigid pipe withinan outer rigid pipe. In an exemplary embodiment, the method furtherincludes positioning the outer rigid pipe at a location at which the atleast one insulated pipeline will be used to convey fluidic materialsthrough the interior of the first pipe, and manufacturing the at leastone insulated pipeline by radially expanding and plastically deformingthe inner rigid pipe within the outer rigid pipe while the inner andouter rigid pipes are both positioned at the location at which the atleast one insulated pipeline will be used to convey fluidic materialsthrough the interior of the first pipe. In an exemplary embodiment, thelocation at which the at least one insulated pipeline will be used toconvey fluidic materials through the interior of the first pipe is belowa body of water.

A method of manufacturing an insulated wellbore casing within a boreholethat traverses a subterranean formation and includes a first wellborecasing coupled to and positioned within the wellbore has been describedthat includes positioning a second wellbore casing having a plurality ofspaced apart resilient sleeves coupled to the exterior surface of thefirst pipe within the first wellbore casing, and radially expanding andplastically deforming the second wellbore casing until the resilientsleeves engage the interior surface of the second pipe. In an exemplaryembodiment, the method further includes injecting an insulating materialinto an annulus defined between the first and second wellbore casings.In an exemplary embodiment, injecting the insulating material into theannulus defined between the first and second wellbore casings includesinjecting the insulating material into the annulus defined between thefirst and second wellbore casings before radially expanding andplastically deforming the first pipe. In an exemplary embodiment,injecting the insulating material into the annulus defined between thefirst and second wellbore casings includes injecting the insulatingmaterial into the annulus defined between the first and second wellborecasings after radially expanding and plastically deforming the secondwellbore casing. In an exemplary embodiment, the second wellbore casingfurther includes a plurality of thermal insulating sleeves coupled tothe exterior surface of the second wellbore casing and interleaved amongthe resilient sleeves.

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the invention. For example, the teachings ofthe present illustrative embodiments may be used to provide an insulatedwellbore casing, a pipeline, or a structural support. Furthermore, theelements and teachings of the various illustrative embodiments may becombined in whole or in part in some or all of the illustrativeembodiments.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1. A method of manufacturing an insulated pipeline, comprising:positioning a first pipe having a plurality of spaced apart resilientsleeves coupled to the exterior surface of the first pipe within asecond pipe; and radially expanding and plastically deforming the firstpipe until the resilient sleeves engage the interior surface of thesecond pipe.
 2. The method of claim 1, further comprising: injecting aninsulating material into an annulus defined between the first and secondpipes.
 3. The method of claim 2, wherein injecting the insulatingmaterial into the annulus defined between the first and second pipescomprises: injecting the insulating material into the annulus definedbetween the first and second pipes before radially expanding andplastically deforming the first pipe.
 4. The method of claim 2, whereininjecting the insulating material into the annulus defined between thefirst and second pipes comprises: injecting the insulating material intothe annulus defined between the first and second pipes after radiallyexpanding and plastically deforming the first pipe.
 5. The method ofclaim 1, wherein the first pipe further comprises: a plurality ofthermal insulating sleeves coupled to the exterior surface of the firstpipe and interleaved among the resilient sleeves.
 6. The method of claim1, wherein positioning the first pipe having the plurality of spacedapart resilient sleeves coupled to the exterior surface of the firstpipe within the second pipe comprises: positioning the second pipebeneath a body of water; and positioning the first pipe having theplurality of spaced apart resilient sleeves coupled to the exteriorsurface of the first pipe within the second pipe.
 7. A system formanufacturing an insulated pipeline, comprising: means for positioning afirst pipe having a plurality of spaced apart resilient sleeves coupledto the exterior surface of the first pipe within a second pipe; andmeans for radially expanding and plastically deforming the first pipeuntil the resilient sleeves engage the interior surface of the secondpipe.
 8. The system of claim 7, further comprising: means for injectingan insulating material into an annulus defined between the first andsecond pipes.
 9. The system of claim 8, wherein means for injecting theinsulating material into the annulus defined between the first andsecond pipes comprises: means for injecting the insulating material intothe annulus defined between the first and second pipes before radiallyexpanding and plastically deforming the first pipe.
 10. The system ofclaim 8, wherein means for injecting the insulating material into theannulus defined between the first and second pipes comprises: means forinjecting the insulating material into the annulus defined between thefirst and second pipes after radially expanding and plasticallydeforming the first pipe.
 11. The system of claim 7, wherein the firstpipe further comprises: a plurality of thermal insulating sleevescoupled to the exterior surface of the first pipe and interleaved amongthe resilient sleeves.
 12. The system of claim 7, wherein means forpositioning the first pipe having the plurality of spaced apartresilient sleeves coupled to the exterior surface of the first pipewithin the second pipe comprises: means for positioning the second pipebeneath a body of water; and means for positioning the first pipe havingthe plurality of spaced apart resilient sleeves coupled to the exteriorsurface of the first pipe within the second pipe.
 13. A method ofmanufacturing an insulated pipeline comprising an inner rigid pipepositioned within, coupled to, and thermally insulated from an outerrigid pipe, comprising: manufacturing the insulated pipeline by radiallyexpanding and plastically deforming the inner rigid pipe within theouter rigid pipe.
 14. The method of claim 13, further comprising:positioning the outer rigid pipe at a location at which the insulatedpipeline will be used to convey fluidic materials through the interiorof the first pipe; and manufacturing the insulated pipeline by radiallyexpanding and plastically deforming the inner rigid pipe within theouter rigid pipe while the inner and outer rigid pipes are bothpositioned at the location at which the insulated pipeline will be usedto convey fluidic materials through the interior of the first pipe. 15.The method of claim 14, wherein the location at which the insulatedpipeline will be used to convey fluidic materials through the interiorof the first pipe is below a body of water.
 16. A system formanufacturing an insulated pipeline comprising an inner rigid pipepositioned within, coupled to, and thermally insulated from an outerrigid pipe, comprising: means for manufacturing the insulated pipelineby radially expanding and plastically deforming the inner rigid pipewithin the outer rigid pipe.
 17. The system of claim 16, furthercomprising: means for positioning the outer rigid pipe at a location atwhich the insulated pipeline will be used to convey fluidic materialsthrough the interior of the first pipe; and means for manufacturing theinsulated pipeline by radially expanding and plastically deforming theinner rigid pipe within the outer rigid pipe while the inner and outerrigid pipes are both positioned at the location at which the insulatedpipeline will be used to convey fluidic materials through the interiorof the first pipe.
 18. The system of claim 17, wherein the location atwhich the insulated pipeline will be used to convey fluidic materialsthrough the interior of the first pipe is below a body of water.
 19. Athermally insulated pipeline, comprising: a plastically deformed firstpipe; a plurality of spaced apart resilient sleeves coupled to theexterior of the first pipe; and a second pipe coupled to the resilientsleeves.
 20. The insulated pipeline of claim 19, further comprising:thermal insulating material positioned within an annulus defined betweenthe first and second pipes and interleaved among the resilient sleeves.21. The insulated pipeline of claim 20, wherein one or more of theresilient sleeves include one or more longitudinal passages.
 22. Theinsulated pipeline of claim 21, wherein at least some of the thermalinsulating material is positioned within the longitudinal passages. 23.A method of operating a hydrocarbon production system for processinghydrocarbons that includes one or more hydrocarbon production sourcesand one or more hydrocarbon production destinations, comprising:conveying hydrocarbons between the hydrocarbon production sources andthe hydrocarbon destinations using one or more insulated pipelines; andmanufacturing at least one of the insulated pipelines by radiallyexpanding and plastically deforming an inner rigid pipe within an outerrigid pipe.
 24. The method of claim 23, further comprising: positioningthe outer rigid pipe at a location at which the at least one insulatedpipeline will be used to convey fluidic materials through the interiorof the first pipe; and manufacturing the at least one insulated pipelineby radially expanding and plastically deforming the inner rigid pipewithin the outer rigid pipe while the inner and outer rigid pipes areboth positioned at the location at which the at least one insulatedpipeline will be used to convey fluidic materials through the interiorof the first pipe.
 25. The method of claim 24, wherein the location atwhich the at least one insulated pipeline will be used to convey fluidicmaterials through the interior of the first pipe is below a body ofwater.
 26. A method of manufacturing an insulated wellbore casing withina borehole that traverses a subterranean formation and includes a firstwellbore casing coupled to and positioned within the wellbore,comprising: positioning a second wellbore casing having a plurality ofspaced apart resilient sleeves coupled to the exterior surface of thefirst pipe within the first wellbore casing; and radially expanding andplastically deforming the second wellbore casing until the resilientsleeves engage the interior surface of the second pipe.
 27. The methodof claim 26, further comprising: injecting an insulating material intoan annulus defined between the first and second wellbore casings. 28.The method of claim 27, wherein injecting the insulating material intothe annulus defined between the first and second wellbore casingscomprises: injecting the insulating material into the annulus definedbetween the first and second wellbore casings before radially expandingand plastically deforming the second wellbore casing.
 29. The method ofclaim 27, wherein injecting the insulating material into the annulusdefined between the first and second wellbore casings comprises:injecting the insulating material into the annulus defined between thefirst and second wellbore casings after radially expanding andplastically deforming the second wellbore casing.
 30. The method ofclaim 26, wherein the second wellbore casing further comprises: aplurality of thermal insulating sleeves coupled to the exterior surfaceof the second wellbore casing and interleaved among the resilientsleeves.
 31. A method of manufacturing an insulated pipeline,comprising: positioning a first pipe having a plurality of spaced apartresilient sleeves coupled to the exterior surface of the first pipewithin a second pipe; radially expanding and plastically deforming thefirst pipe until the resilient sleeves engage the interior surface ofthe second pipe; and injecting an insulating material into the annulusdefined between the first and second pipes before radially expanding andplastically deforming the first pipe.
 32. A method of manufacturing aninsulated pipeline, comprising: positioning a first pipe having aplurality of spaced apart resilient sleeves coupled to the exteriorsurface of the first pipe within a second pipe; radially expanding andplastically deforming the first pipe until the resilient sleeves engagethe interior surface of the second pipe; and injecting an insulatingmaterial into the annulus defined between the first and second pipesafter radially expanding and plastically deforming the first pipe.
 33. Amethod of manufacturing an insulated pipeline, comprising: positioning afirst pipe having a plurality of spaced apart resilient sleeves coupledto the exterior surface of the first pipe within a second pipe; radiallyexpanding and plastically deforming the first pipe until the resilientsleeves engage the interior surface of the second pipe; and injecting aninsulating material into the annulus defined between the first andsecond pipes before and after radially expanding and plasticallydeforming the first pipe.
 34. A method of manufacturing an insulatedpipeline, comprising: positioning a first pipe having a plurality ofspaced apart resilient sleeves coupled to the exterior surface of thefirst pipe within a second pipe; and radially expanding and plasticallydeforming the first pipe until the resilient sleeves engage the interiorsurface of the second pipe; and injecting an insulating material intothe annulus defined between the first and second pipes; wherein thefirst pipe further comprises a plurality of thermal insulating sleevescoupled to the exterior surface of the first pipe and interleaved amongthe resilient sleeves.
 35. A method of manufacturing an insulatedpipeline, comprising: positioning a first pipe beneath a body of water;positioning a second pipe having the plurality of spaced apart resilientsleeves coupled to the exterior surface of the second pipe within thefirst pipe; radially expanding and plastically deforming the second pipeuntil the resilient sleeves engage the interior surface of the firstpipe; and injecting an insulating material into the annulus definedbetween the first and second pipes; wherein the second pipe furthercomprises a plurality of thermal insulating sleeves coupled to theexterior surface of the first pipe and interleaved among the resilientsleeves.
 36. A system for manufacturing an insulated pipeline,comprising: means for positioning a first pipe having a plurality ofspaced apart resilient sleeves coupled to the exterior surface of thefirst pipe within a second pipe; means for radially expanding andplastically deforming the first pipe until the resilient sleeves engagethe interior surface of the second pipe; and means for injecting aninsulating material into the annulus defined between the first andsecond pipes before radially expanding and plastically deforming thefirst pipe.
 37. A system for manufacturing an insulated pipeline,comprising: means for positioning a first pipe having a plurality ofspaced apart resilient sleeves coupled to the exterior surface of thefirst pipe within a second pipe; means for radially expanding andplastically deforming the first pipe until the resilient sleeves engagethe interior surface of the second pipe; and means for injecting aninsulating material into the annulus defined between the first andsecond pipes after radially expanding and plastically deforming thefirst pipe.
 38. A system for manufacturing an insulated pipeline,comprising: means for positioning a first pipe having a plurality ofspaced apart resilient sleeves coupled to the exterior surface of thefirst pipe within a second pipe; means for radially expanding andplastically deforming the first pipe until the resilient sleeves engagethe interior surface of the second pipe; and means for injecting aninsulating material into the annulus defined between the first andsecond pipes before and after radially expanding and plasticallydeforming the first pipe.
 39. A system for manufacturing an insulatedpipeline, comprising: means for positioning a first pipe having aplurality of spaced apart resilient sleeves coupled to the exteriorsurface of the first pipe within a second pipe; means for radiallyexpanding and plastically deforming the first pipe until the resilientsleeves engage the interior surface of the second pipe; and means forinjecting an insulating material into the annulus defined between thefirst and second pipes; wherein the first pipe further comprises aplurality of thermal insulating sleeves coupled to the exterior surfaceof the first pipe and interleaved among the resilient sleeves.
 40. Asystem for manufacturing an insulated pipeline, comprising: means forpositioning a first pipe beneath a body of water; means for positioninga second pipe having the plurality of spaced apart resilient sleevescoupled to the exterior surface of the second pipe within the firstpipe; means for radially expanding and plastically deforming the secondpipe until the resilient sleeves engage the interior surface of thefirst pipe; and means for injecting an insulating material into theannulus defined between the first and second pipes; wherein the secondpipe further comprises a plurality of thermal insulating sleeves coupledto the exterior surface of the first pipe and interleaved among theresilient sleeves.
 41. A method of manufacturing an insulated pipelinecomprising an inner rigid pipe positioned within, coupled to, andthermally insulated from an outer rigid pipe, comprising: manufacturingthe insulated pipeline by radially expanding and plastically deformingthe inner rigid pipe within the outer rigid pipe; positioning the outerrigid pipe at a location at which the insulated pipeline will be used toconvey fluidic materials through the interior of the first pipe; andmanufacturing the insulated pipeline by radially expanding andplastically deforming the inner rigid pipe within the outer rigid pipewhile the inner and outer rigid pipes are both positioned at thelocation at which the insulated pipeline will be used to convey fluidicmaterials through the interior of the first pipe; wherein the locationat which the insulated pipeline will be used to convey fluidic materialsthrough the interior of the first pipe is below a body of water.
 42. Asystem for manufacturing an insulated pipeline comprising an inner rigidpipe positioned within, coupled to, and thermally insulated from anouter rigid pipe, comprising: means for manufacturing the insulatedpipeline by radially expanding and plastically deforming the inner rigidpipe within the outer rigid pipe; means for positioning the outer rigidpipe at a location at which the insulated pipeline will be used toconvey fluidic materials through the interior of the first pipe; andmeans for manufacturing the insulated pipeline by radially expanding andplastically deforming the inner rigid pipe within the outer rigid pipewhile the inner and outer rigid pipes are both positioned at thelocation at which the insulated pipeline will be used to convey fluidicmaterials through the interior of the first pipe; wherein the locationat which the insulated pipeline will be used to convey fluidic materialsthrough the interior of the first pipe is below a body of water.
 43. Athermally insulated pipeline, comprising: a plastically deformed firstpipe; a plurality of spaced apart resilient sleeves coupled to theexterior of the first pipe; a second pipe coupled to the resilientsleeves; and thermal insulating material positioned within an annulusdefined between the first and second pipes and interleaved among theresilient sleeves; wherein one or more of the resilient sleeves includeone or more longitudinal passages; and wherein at least some of thethermal insulating material is positioned within the longitudinalpassages.
 44. A method of operating a hydrocarbon production system forprocessing hydrocarbons that includes one or more hydrocarbon productionsources and one or more hydrocarbon production destinations, comprising:conveying hydrocarbons between the hydrocarbon production sources andthe hydrocarbon destinations using one or more insulated pipelines;manufacturing at least one of the insulated pipelines by radiallyexpanding and plastically deforming an inner rigid pipe within an outerrigid pipe; positioning the outer rigid pipe at a location at which theat least one insulated pipeline will be used to convey fluidic materialsthrough the interior of the first pipe; and manufacturing the at leastone insulated pipeline by radially expanding and plastically deformingthe inner rigid pipe within the outer rigid pipe while the inner andouter rigid pipes are both positioned at the location at which the atleast one insulated pipeline will be used to convey fluidic materialsthrough the interior of the first pipe; wherein the location at whichthe at least one insulated pipeline will be used to convey fluidicmaterials through the interior of the first pipe is below a body ofwater.
 45. A method of manufacturing an insulated wellbore casing withina borehole that traverses a subterranean formation and includes a firstwellbore casing coupled to and positioned within the wellbore,comprising: positioning a second wellbore casing having a plurality ofspaced apart resilient sleeves coupled to the exterior surface of thefirst pipe within the first wellbore casing; radially expanding andplastically deforming the second wellbore casing until the resilientsleeves engage the interior surface of the second pipe; and injectingthe insulating material into the annulus defined between the first andsecond wellbore casings before radially expanding and plasticallydeforming the second wellbore casing.
 46. A method of manufacturing aninsulated wellbore casing within a borehole that traverses asubterranean formation and includes a first wellbore casing coupled toand positioned within the wellbore, comprising: positioning a secondwellbore casing having a plurality of spaced apart resilient sleevescoupled to the exterior surface of the first pipe within the firstwellbore casing; radially expanding and plastically deforming the secondwellbore casing until the resilient sleeves engage the interior surfaceof the second pipe; and injecting the insulating material into theannulus defined between the first and second wellbore casings afterradially expanding and plastically deforming the second wellbore casing.47. A method of manufacturing an insulated wellbore casing within aborehole that traverses a subterranean formation and includes a firstwellbore casing coupled to and positioned within the wellbore,comprising: positioning a second wellbore casing having a plurality ofspaced apart resilient sleeves coupled to the exterior surface of thefirst pipe within the first wellbore casing; radially expanding andplastically deforming the second wellbore casing until the resilientsleeves engage the interior surface of the second pipe; and injectingthe insulating material into the annulus defined between the first andsecond wellbore casings after radially expanding and plasticallydeforming the second wellbore casing; wherein the second wellbore casingfurther comprises a plurality of thermal insulating sleeves coupled tothe exterior surface of the second wellbore casing and interleaved amongthe resilient sleeves.
 48. An hydrocarbon production system forprocessing hydrocarbons that includes one or more hydrocarbon productionsources and one or more hydrocarbon production destinations, comprising:means for conveying hydrocarbons between the hydrocarbon productionsources and the hydrocarbon destinations using one or more insulatedpipelines; means for manufacturing at least one of the insulatedpipelines by radially expanding and plastically deforming an inner rigidpipe within an outer rigid pipe; means for positioning the outer rigidpipe at a location at which the at least one insulated pipeline will beused to convey fluidic materials through the interior of the first pipe;and means for manufacturing the at least one insulated pipeline byradially expanding and plastically deforming the inner rigid pipe withinthe outer rigid pipe while the inner and outer rigid pipes are bothpositioned at the location at which the at least one insulated pipelinewill be used to convey fluidic materials through the interior of thefirst pipe; wherein the location at which the at least one insulatedpipeline will be used to convey fluidic materials through the interiorof the first pipe is below a body of water.
 49. A system formanufacturing an insulated wellbore casing within a borehole thattraverses a subterranean formation and includes a first wellbore casingcoupled to and positioned within the wellbore, comprising: means forpositioning a second wellbore casing having a plurality of spaced apartresilient sleeves coupled to the exterior surface of the first pipewithin the first wellbore casing; means for radially expanding andplastically deforming the second wellbore casing until the resilientsleeves engage the interior surface of the second pipe; and means forinjecting the insulating material into the annulus defined between thefirst and second wellbore casings before radially expanding andplastically deforming the second wellbore casing.
 50. A system formanufacturing an insulated wellbore casing within a borehole thattraverses a subterranean formation and includes a first wellbore casingcoupled to and positioned within the wellbore, comprising: means forpositioning a second wellbore casing having a plurality of spaced apartresilient sleeves coupled to the exterior surface of the first pipewithin the first wellbore casing; means for radially expanding andplastically deforming the second wellbore casing until the resilientsleeves engage the interior surface of the second pipe; and means forinjecting the insulating material into the annulus defined between thefirst and second wellbore casings after radially expanding andplastically deforming the second wellbore casing.
 51. A system formanufacturing an insulated wellbore casing within a borehole thattraverses a subterranean formation and includes a first wellbore casingcoupled to and positioned within the wellbore, comprising: means forpositioning a second wellbore casing having a plurality of spaced apartresilient sleeves coupled to the exterior surface of the first pipewithin the first wellbore casing; means for radially expanding andplastically deforming the second wellbore casing until the resilientsleeves engage the interior surface of the second pipe; and means forinjecting the insulating material into the annulus defined between thefirst and second wellbore casings after radially expanding andplastically deforming the second wellbore casing; wherein the secondwellbore casing further comprises a plurality of thermal insulatingsleeves coupled to the exterior surface of the second wellbore casingand interleaved among the resilient sleeves.